Manufacture of armatures



March 6, 192s. I 1,661,332

A. B. GOMORY MANUFACTURE OF ARMATURES Original Filed Feb. 5, 1925 *ENif, 2e. f 3 55 H. V

5 Sheets-Sheet l March 6, 1928. 1,661,332

A. B. GOMORY MANUFACTURE OF ARMATURES Original Filed Feb. 5, 1925 3Sheets-Sheet 2 NEE U MIU/95555 v fnUEz-JZLU? M/MM bivs Zal-'neg March 6,1928.

A. B. GOMORY MANUFACTURE 0F ARMATURES Original Filed Feb. 5, 1925Z/LHESEES @gpm/ZM #Patent/ed, Maraplg@ Y UNITED STATES PATENT OFFICE.

.ALBERT B. GOHORY, 0F ANDERSON, INDIANA, ASSIGNOB, BY MESNE ASSIGNMENTS,T0 DELCO-REMY CORPORATION, 0F DAYTON, OHIO, .A CORPORATION OF DELAWARE.

MANUFAC'F'URE 0F IARIATURES. l

Continuation of application vSerial No. 616,842, led lFebruary 3,19.2.3. This application med November 1924. lserial No. 751,183.

This invention relates to the manufacture of armatures fordynamo-electric machines and particularly to armatures having openslotted cores.

This application is a continuation of my former application, Serial No.616,842 filed February 3, 1923.

One object is to provide an improved proc ess of winding the armatureconductors upon the core in order .to secure compactness of the windingsand to facilitate the attachment of the terminals thereofto thecommutator bars.

Other and further objects of.v the present invention will be apparentfrom the following description, reference being had tothe accompanyingdrawings, wherein a preferred embodiment of the present invention isclearly shown.

In the drawings:

Fig. l is a perspective view of an armature showing the rst armaturecoil wound thereon together wit-hthe handle assembled on the armatureshaft, -said handle being employed in the armature winding process;

Figs. 2 and 3 are diagrams illustrating the winding process;

Fig. 4 is an end view of a completely wound armature showing theends ofthe armature coils.

The armature shown in Fig. 1 includes a shaft 30 and a laminated core33. This assembly of laminations provides a core having a plurality ofteeth T1, T2, T3, etc., which include slots S1, S2, S, etc.

The core laminations are held upon the shaft by a press fit over theknurled portion thereof,and each end of the core is provided with aninsulating disc 36 of the same contour as the laminations. Adjacent thediscs' 36 the shaft 30 is provided with insulating tubes 37 and 38,formed preferably by wrapping on the shaft several turns of insulatingpaper, the free. end of the paper strip being held down by paste. Thecore slots areinsulated with strips of suitable nonconducting paper.

The wires for forming the armature `coils are unwound from spools orreels of wire land each coil includes a plurality of turns, six turns inthe example given. Two wires are wound pon the core simultaneously, andthese w es are distinguished by providing one with white insulation andthe other with colored insulation. It is the aim of the invention towind the armature in such a manner that the terminals of the coils willno t be packed down' against the shaft insulating tube 37 as the coilsare successively wound upon the core but will be packed by theoverlapping portions of the coils against the core insulating disc 36.When the armature disclosed is completel wound there will be 14 coils ofwire wit white insulation and.l 14 coils of wire with coloredinsulation, making a total of 28 coils and 56 coil terminals which areto be connected with the 28 commutator bars afterthe winding process iscomplete. By referring to Fig. 4 it will be noted that all of theseterminals are broughtout along the core insulating disc4 36 and thatnone of these terminal Wires have been packed down against the armatureshaft duringthe winding process. l

The bottom terminals of the coils are designated 1B, 2B, etc., while thetop terminals are designated 1T, 2T, etc. It will be noted that thebottom terminals are cut oit' shorter than the top terminals, andsincethe two coils which are wound simultaneously are distinguishedbythe color of the insulation, there will be no diiculty in identifyingthe terminals of the different coils. There will be no diiliculty inlocating the last coils wound on, namely coil 14 white and coil 14colored, because, `as shown in Fig. 4 these coils overlap all of theother coils and their top terminals are cut off longer than the other toterminals.

In or er to produce these results, the-wires joining the progressivelywound armature coils are formed intoloops, and these loops are severedin two places differing in distance from the armature core whereby tomake the top' terminals or leads from the armature coils longer than thebottom leads. Between successive winding o rations some of 'these leadsare bent away rom the plane of the winding of the coils so that theoverlapping portions of the coils cannot push the previousl formed coilterminals down against t e insulating tube 37. In other words, thewinding must rooeed in such aA way that the coil termina s canrbebrought out alongside the-insulation disc 36, and so as not to bepressed down by the successive coil 'winding operations against the tube37.

ess.

In order to facilitate this process of winding, there is provided;v ahandle or sleeve 70 sha t as shown in Fig. 1. The handle is.

provided with a peg 71and with a plurality of hooks 72. The drawingsshow a handle having 14 hooks, one for each of the 14 slots of thearmature core which has been selected as an example to illustrate thewinding proc- The handle includes a sleeve 73 having an internaldiameter-sufficient torcceive that portion of the armature to the rightof the armature insulation 37 shown in Fig. 1 but the internal diameterof the sleeve 73 is less than. the external diameter of insulation 71Vso that this vinsulation acts as (stop to limit the movement of thehandle 70 to- The sleeve is provided with a shoulder 74 which serves asa guide forv the blades of a pair of Wire snippers so that the bottomleads or ends extending from the first turns of the coils will all besevered off a uniform distance from the armature core. The sleeve 73 isprovided with a groove 75 which serves as aguide for the snipper bladesto facilitate cutting off the top leads or ends from the last turns ofthe coils at a uniform distance from the armature core and so that thetop leads or terminals will be longer as measured from the core, thanthe bottom leads.

The present method of making an arma# ture may be carried on by anarmature Windi ing machine of the type disclosed in my copendingapplication, Serial No. 740,058, filed September 26, 1924, but,obviously, may be carried on Without the aid of a winding machine, oreven the handle or sleeve 70, although' this sleeve facilitates theloopforming operation between successive Winding operations.

The ends of the wires 76, and 77, which are to be. wound upon thearmature core, are rst twisted around the peg 71 ofthe handle 70, andthe wires are Wound into certain spaced slots marked SI and S" inFig. 1. S1 denotes the slot which receives the starting-active-coil sideof the first coil 'to be wound, and the slot S receives the endin-active-coil side of thiscoil.

ig. 1 shows the first pair of coils to be wound on. The first or bottomturn of each coil extends through slot Sl and across the back of thecore (the face of the core remote from the commutator) and then towardthe commutator end of the armature through the slot S". In the examplegiven each coil includes 6 turns. The bottom terminals of the pair ofcoils are designated by 1B white and 1B colored in Fig. 1 and includethat portion of the wire between the peg 71 and the slot S1. The leadslfrom the last turns of the first coilto be wound on are designated 1Twhite and 1T coloredv in Fig. l, and these mensen ends are hooked overthe hook H2 and ithese wires which proceed from the hook .l-I2 will formthe bottom leads of the second coil wound on. Y Therefore theseleadsare-lues" ignated 2B wlnte and 2B colored. After the first coil hasbeen'wound on, the ends of wires 76 and 77 are unwound from the peg 7land are Wrapped around the hook H.

Between successive coil winding opera tions the armature shaft isrotated through an angle defined by the pitch of the core slots so as tobring the next pair of spaced core slots. into cooperative relation tothe wire guides-of the machine.

lf the winding of the second pair of coils Vwere to proceed withoutclipping the coil terminals 1B white and 1B colored, it is apparent fromFig. 1 that a portion of the second coil wound on would overlap theseleads or terminals because a portion of the coil would extend across thecore insulating disc 36 between the slots S2 and S1". This portion wouldpress the terminals 1B White and -1n colored down against the insulatingtube 37. If none of the coil leadsrwere clipped during successive coilwinding operations, and the clipping ofthe leads were to be postponeduntil all of the coils were Wound on, the result would be that theoverlapping portions of these coils, which are clearly shown in Fig. 4,would press all of the bottom leads of the coils and the first sevenpair of top leads down against the insulating tube 37 whereas the lastseven pair of topleads would require the placing ofthe commutator atsuch a distance from the core as to permit bringing these bottom leadsand top leads in the first seven coils around the end of the armaturecoils and the space would have to `be sufiicient for properly insulatingthese leads from the overlapping portions of the coils, and there wouldneedtO be some abrupt bends made in some of the leads before they arebrought out to their. respective commutator bars; Such a constructionWould take up more room than nec-v essary and would require additionallabor to apply the necessary insulating material.'

But if the coil leads are all brought out alongside the core insulatingdisc 36, that is packed in between thisdisc and the overlapping portionsof the armature coils, then the insulation of these leads and theiratltachment to the commutator bars .Will be much simplified and thespacerequired will be materially reduced.. Therefore before any subsequentpair 'of coils are wound on,

Ilm

the bottom leads of theV preceding pair of f -coils are severedbycutting these Wires at X in. Fig.. 1 which is done by applying theviremsnlppers 4along the vedge of the shoul- The winding process -isillustrated dia-4 or more coils simultaneously.

consideredas one wire, since the recess disclosed can be applied to thewin ing of one The core teeth are desi nated by T1 to T, the slots varedesignate yb Sl to S, and the coils by CL to C. lhs respective coils aredesignated by l1B to 14B, respectively, and the top leads are designatedby 1T to 14T, respectively. The cut` ting lines 7 4x in Figs. 2 and 3represents the shoulder 74 shown in Fig. 1. The cutting.

line 7 5X designates the groove 75 shown in Fig. 1. The different hooks72 shown in Fig. 1 are designated by H1 to H1* in Figs. 2 and 3, onehook for each of the slots S1 to Sl. It will be noted that wherethe lead1B crosses the cutting line 74X, a small is placed to designate that thelead 1B is out along the shoulder 74 of the handle 70, the

'heavy curved line which is designated by the s mbol 19K/2 means thatbefore Winding coil 2,the lead 1B is cut oli along the shoulder 7 4 andis bent away/from the winding region. The heavy curve line designated bythe symbol 2BX/3` denotes that before eoil C3 is wound on, the bottomlead of coil C2 known as 2B is cut olf lalong the Shoulder 74 and movedaway from the winding region so as to be overlapped by coil C3 but bepositioned between coil C3 and the core insulating disc 36. With thisexplanation the meaning of the symbols3Bx/4 in Fig. 2 to the symbol13m/14 will be readily apparent. These symbols simply mean that beforecoils 2 to 14 are i Wound on, the bottom leads of coils C1 to C13 aresevered, respectively. It is apparent that since coil C1* is the'lastone on, its bottom lead 14B will not be severed until after the windingoperation is complete. The symbol 1413"/ end is used to designate thisstep.

It is apparent in Fig. 1 that until ,the first eight coils 'are woundon, Athe top leads of the preceding seven coils need not be clipped. Butsince the coil C enters the slot SAin which a rtion of coil Cl iscontained, the top l of coil C1, lead 1T, must be severed and moved outof the winding region. Since it is desired to have the top leads longerthan the bottom `leads in order to distinguish them, the top leads withthe exception of 14T are severed adjacent the notch 75. Referr` to Fig.3, the ints ofintersection of e lines 75I wi the leads 1T to 13'1`aredesignated by a; to denote bol 1/9 applied to bottom leads of the' justbelow it, denotes that 1T is cut at the groove'75 before coil C isapplied. The curve line designated by the symbol 2Tx/9 or 10 designatesthat the terminal 2T must be out olf at groove 75 and bent to one sidebefore coil C is applied or at least before the Winding of coil C10. Theterminals 7T to 14T need not be severed until the end of the Windingoperation. The lead 14T is not severed at the groove 75 but thisterminal is cut off longer than the others in order to make it clearlydistinguishable, and instead of Wrapping 14T around hook l this lead issimply wrapped around the other leads to hold. them in position afterthe armature is removed from the winding machine. In other words theleads are notl all spread out as shown in Fig. 4 but are tucked downalong the armature shaft after the handle has been removed and the longlead 14T is used to hold the other leads temporarily in position.

The next step in the manufacture of the armature is to mount upon thearmature shaft a commutator which is substantially complete except formachining the commutator bars. Such a commutator is shown at 100 in Fig.4, and has bars which are insulated by mica segments in the usual mannerand the commutator is mounted upon the shaft so that every other micastrip is in substantial alignment with the end of a core slot.' The nextstep is' to provide one of the commutator bars with a distinguish-v ingmark in order to'facilitate the operation of connecting the armaturecore leads with the proper commutator bars. Looking at the eomrnutatorend of the armature as viewed in Fig. 4, the terminals 14T are clearlydistinguishable since they come out on top and. emanate from a coilwhich overlaps all of the other coils and therefore must be coil 014.The terminals 14T-are also distinguishable from the outside terminalsbecause these are longer than any of the others. The overlapping portionof coil C1 which is visible in Fig. 4, extends from slot S14 to slot S8.Beginning with slot S, which is of course the slot where coil 14C firstenters, the operator will count three slots moving in a counterclockwisedirect-ion and arrive at the slot S12. The commutator bar which isimmediately to the left of the center line of slot S12 is marked by aprick punch as indicated at 102 to denote that this bar is bar No. 1meaning the one to which the bottom lead of the coil No. 1 ofwhite'insulated wire (designated 1n white) is connected. The wires 2B.white to 14B white are connected with commutator bars #3, #5, #7, etc.,to bar #27, rcspectivelyv These leads are wrapped with insulation' andleads 1n colored to 14B colored are connectedwith comlnutator bars #2,#4, #6, etc., to bar #28, respectively. These leadsare wrapped withinsulation and leads 1T white to ll'tv cluding a core having any numberof slots,

and the pitch of the armature coils may be different from that shown inthe drawings. lin any case the bottom lead of any coil must be severedand bent away from the winding region'of the nextcoil to be wound beforethe nextsucceeding coil is wound on. lBy bending a lead away from thewinding re` gion of the next coil to be wound is meant to bend the leadrelative to the active-coilside from which it continues in such adirection that it will not be overlapped by the end portions of the nextcoil to be wound upon the core.

Letting S be the number of slots, and T, the number of core teethembraced by a coil, when S-'l coils have been wound on, all of the slotswill contain a portion of at least one coil. Therefore before the nextcoil is wound-on the'toplead of the first coil must besevered and movedout of the winding region of the next coil to be wound. Generallystated, the present process includes the steprof cutting the top lead ofthe Nth coil before the (N+S-'ll`)th coil is wound on, N being the ordernumber of the A coil whose top lead is severed. For example,

if there are fourteen slots andsix teeth are embraced by the coil, thenthe top `lead of the first coil must be cut before the. (Fria-@th or9th' coil is wound on, the top lead of the second coil mustfbe cutbefore the (2+l4-6)th or 10th coil is wound on etc. Ubviously if onlyfourteen coils are wound on, then after the fourteenth coil has beenwound, the clipping of lthe coils after the sixth will bey done at theendof the -winding operation.

While the process and form of mechanism herein shown and 'describedconstitutes a preferred embodiment of the invention, it

is to-be understood that other forms might be adopted, all coming withinthe scope of `the claims which follow.

What is claimed `is as follows:`

l. The process of making an armature which includes winding successivelyupon an open slotted armature core a plurality of ,coils of wire,providing between successive coils a loop of wire one branchof whichleads from the endmg active-coil-side of they preceding coil and theother branch of which leads to the starting active-coil-side of theneanaaa next .succeeding coil; and' in severing the loop branch leadinto the starting activecoil-side of a prece ing coil to provide separatedcoil leads for said preceding coil, and in bending the lead of startingactive-coil-v side of the preceding coil away from the winding region ofthe next coil to be wound before-winding the next succeeding coil inorder that the severed lead may bebrought out between the end of thecore and the wire conductors overlapping the end of the core.

2. The process of making an armature according to claim l and includingin addition thereto the following step which is introduced beforewinding a coil into a slot already containing an active-coil-side of apreviously wound coil, namely: the step of bending the ending leadcontinuing from said previously wound, active-coil-side away from thewinding region of the next coil to be wound before winding said nextcoil, in order that said lead may be brought out between the end of thecore andthe wires overlapping the end of the core.

3. The process of making an armature which includes assembling a slottedcore upon a shaft, placing upon the shaft a sleeve carrying, a pluralityof angularly spaced hooks located a substantial distance from the core,progressively winding coils of wire into slots of a certain spacing,providing between successive coil winding operations a loop of wire-,thebranches of which provide the-ending lead of a preceding coil and thestarting lead of the next succeeding coil, said loop being formed bypassing the wire extending from the ending active-coiLside away from thewinding region of the next .coil to be wound beforevproceeding to wind1t, the remaining portion of the severed loop remaining bent around saidhook, the process including in addition to the foregoing, the followingsteps which are introduced before windingv into a slot .containing theending active-coil-side of a previously wound coil, namely :the step offreeing from its hook the ending lead of a previously wound coil whoseending activehcoil-side is in a slot next to receive a coil, and thestep of bending said ending lead away from the winding region of thenext coil to be wound.

fi. An armature for dynamo-electric machlnes comprising in combination,a slotted core, a commutator, and a plurality of coils each embracingaplurality of core teeth and having leads for connecting the coils withllt) certain bars of the commutator, the coilsl overlapping each otherat the ends of .the core, and the leads which continue from turns of thecoils which are underneath other turns extending from the coils tothecommutator from between the'encl of the core and the overlapping coilportions adjacent that end of the core.

5. An armature for dynamo-electric machines comprising, in combination,a slotted core7 a eommutator, and a plurality of coils each embracing aplurality of core teeth, and having leads for connecting the coils withcertain bars of the commutator, the coils overlapping each otherattheends of the core, each core slot receiving portions of a plurality ofcoils, the start and end leads of coils underneath other coils and thestart leads of coils overlying other coils .in :i core slotextendingfrom vthe coils tothe uommutator 'from between the end of thecore and the overlapping. coil portions adjacent that end of the core.

In testimony whereof I hereto ailix my signature.

ALBERT B. GOMORY.

